Carrier fy5b Installation Instructions Manual

Category
Split-system air conditioners
Type
Installation Instructions Manual

This manual is also suitable for

Installation Instructions
NOTE: Read the entire instruction manual before starting the
installation.
TABLE OF CONTENTS
PAGE
SAFETY CONSIDERATIONS ........................ 1
INTRODUCTION .................................. 1
HEATER PACKAGES .............................. 2
INSTALLATION ................................... 2
Step 1 -- Check Equipment ......................... 2
Step 2 -- Mount Unit .............................. 2
Step 3 -- Air Ducts ............................... 4
Step 4 -- Electrical Connections ..................... 4
Step 5 -- Refrigerant Tubing Connection and Evacuation .. 7
Step 6 -- Refrigerant Flow-Control Device ............. 7
Step 7 -- Condensate Drains ........................ 8
Step 8 -- Accessories .............................. 9
Step 9 -- Sequence of Operation .................... 10
START-UP PROCEDURES ......................... 10
CARE AND MAINTENANCE ....................... 10
AIRFLOW PERFORMANCE TABLES ................ 11
SAFETY CONSIDERATIONS
Improper installation, adjustment, alteration, service, maintenance,
or use can cause explosion, fire, electrical shock, or other
conditions which may cause death, personal injury or property
damage. Consult a qualified installer, service agency, or your
distributor or branch for information or assistance. The qualified
installer or agency must use factory-authorized kits or accessories
when modifying this product. Refer to the individual instructions
packaged with kits or accessories when installing.
Follow all safety codes. Wear safety glasses, protective clothing
and work gloves. Have a fire extinguisher available. Read these
instructions thoroughly and follow all warnings or cautions
included in literature and attached to the unit. Consult local
building codes and the current editions of the National Electrical
Code (NEC) NFPA 70.
In Canada, refer to the current editions of the Canadian Electrical
Code CSA C22A.
Recognize safety information. This is the safety-alert symbol /_.
When you see this symbol on the unit and in instruction manuals,
be alert to the potential for personal injury.
Understand the signal words DANGER, WARNING, and
CAUTION. These words are used with the safety-alert symbol.
DANGER identifies the most serious hazards which will result in
severe personal injury or death. WARNING signifies hazards
which could result in personal injury or death. CAUTION is used
to identify unsafe practices which may result in minor personal
injury or product and property damage. NOTE is used to highlight
suggestions which will result in enhanced installation, reliability, or
operation.
ELECTRICAL OPERATION HAZARD
Failure to follow this warning could result in personal injury
or death.
Before installing or servicing unit, always turn off all power to
unit. There may be more than 1 disconnect switch. Turn off
accessory heater power if applicable. Lock out and tag switch
with a suitable warning label.
CUT HAZARD
Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burrs, Use care and
wear appropriate protective clothing and gloves when
handling parts,
INTRODUCTION
Models FB4C and FY5B are Puron Fan Coils designed for
installation flexibility. These units are designed to meet the low air
leak requirements currently in effect.
FB4C uses a refrigerant piston metering device with an X-13
integral electronically commutated motor for efficiency. These
units have be designed for upflow, downflow (kit required), and
horizontal orientations, including manufactured and mobile home
applications.
FY5B uses a refrigerant piston metering device (018 thru 048) with
2-speed PSC (permanent split capacitor) motors and TXV with
3-speed PSC motor for the 060 size, These units can be used for
upflow or downflow (kit required) orientations, including
manufactured and mobile homes applications.
These units require a field supplied air filter, and are designed
specifically for Puron refrigerant air conditioners and heat pumps
as shipped. These units are available for systems of 18,000 through
60,000 Btuh nominal cooling capacity. Factory-authorized, field -
installed electric heater packages are available in sizes 5 through
30kW. See Product Data literature for all available accessory kits.
HEATER PACKAGES
This unit may or may not be equipped with an electric heater
package. For units not equipped with factory-installed heat, a
factory-approved, field-installed, UL listed heater package is
available from your equipment supplier. See unit rating plate for a
list of factory-approved heaters. Heaters that are not factory
approved could cause damage which would not be covered under
the equipment warranty. If fan coil contains a factory-installed
heater package, minimum circuit ampacity (MCA) and maximum
fuse/breaker may be different than units with a same size
field-installed accessory heater. The differences is not an error and
is due to calculation difference per UL guidelines.
INSTALLATION
Step 1 -- Check Equipment
Unpack unit and move to final location. Remove carton taking care
not to damage unit. Inspect equipment for damage prior to
installation. File claim with shipping company if shipment is
damaged or incomplete.
Locate unit rating plate which contains proper installation
information. Check rating plate to be sure unit matches job
specifications.
Step 2 -- Mount Unit
Unit can stand or lie on floor, or hang from ceiling or wall. Allow
space for wiring, piping, and servicing unit.
IMPORTANT: When unit is installed over a finished ceiling
and/or living area, building codes may require a field-supplied
secondary condensate pan to be installed under the entire unit.
Some localities may allow as an alternative, the running of a
separate, secondary condensate line. Consult local codes for
additional restrictions or precautions.
A. Upflow Installation
If return air is to be ducted through a floor, set unit on floor over
opening and use 1/8 to l/4-in (3 to 6 mm) thick fireproof resilient
gasket between duct, unit, and floor.
Side return is a field option on slope coil models. Cut opening per
dimensions. (See Fig. 1.) A field-supplied bottom closure is
required.
018 048 21" (533 n'lm) FRONT SERVICE
060 060 24" (610ram) CLEARANCE
o 1'112"(3O%m,
024 030 17" 432mm) [
036 19" (483 mm)
A07565
Fig. 1 - Slope Coil []nit in Upllow Application
B. Downflow Installation
In this application, field conversion of the evaporator is required
using accessory downflow kit along with an accessory base kit.
Use fireproof resilient gasket, 1/8 to l/4-in (3 to 6 mm) thick,
between duct, unit, and floor.
[]NIT OR PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in product or property
damage.
The conversion of the fan coil to downflow requires special
procedures for the condensate drains on both A-coil and slope
units. The vertical drains have an overflow hole between the
primary and secondary drain holes. This hole is plugged for all
applications except downflow, but must be used for downflow.
During the conversion process, remove the plastic cap
covering the vertical drains only and discard. Remove the plug
from the overflow hole and discard. At completion of the
downflow installation, caulk around the vertical pan fitting to
door joint to retain the low air leak performance of the unit.
NOTE: To convert units for downflow applications, refer to
Installation Instructions supplied with kit for proper installation.
For slope fan coils, use kit Part No. KFADC0201SLP. For A-coils,
use kit Part No. KFADC0401ACL Use fireproof resilient gasket,
1/8 to l/4-in (3 to 6 mm) thick, between duct, unit, and floor.
NOTE: Gasket kit number KFAHD0101SLP is also required for
all downflow applications to maintain low air leak/low sweat
performance.
C. Horizontal Installation
[]nits must not be installed with access panels facing up or down.
All other units are factory built for horizontal left installation. (See
Fig. 2 and 3.) When suspending unit from ceiling, dimples in
casing indicate suitable location of screws for mounting metal
support straps. (See Fig. 2.)
PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in product or property
damage.
For optimum condensate drainage performance in horizontal
installations, unit should be leveled along its length and width.
For horizontal applications having high return static and humid
return air, the Water Management Kit, KFAHC0125AAA, may
need to be used to assist in water management.
@RIMARY
RAIN
HANGING
STRAPS
LOW voFr
ENTRY
OPTIONS
o#
SECONDARY
DRAIN
018-048 21" (533 turn)
060 060 24" (610 ram)
FRONT SERVICE
CLEARANCE
:ULL FACE
OF UNIT)
175"(44 mm)
FILIERACCESS
CLEARANCE
A07566
Fig. 2 - Slope (;oil []nit in Horizontal Left Application
CONNECTIONS
A00072
Fig. 3 - A-Coil in Horizontal Left Application (Factory
Ready)
NOTE: Modular units can be disassembled and components
moved separately to installation area for reassembly. This process
accommodates small scuttle holes and limiting entrances to
installation sites. (See Fig. 4.)
2SCREWS
I
I
COIL
SUPPORT --
RAIL
SLOPE COIL
SKI
CONNECTIONS
-PRIMARY DRAIN
SECONDARY DRAIN
A03001
Fig. 5 - Conversion for Horizontal Right Applications Using a
Slope Coil
Horizontal Right Conversion of Units With A-Coils
1. Remove blower and coil access panels. (See Fig. 6.)
BRACKET
2 SCREWS
A95293
Fig. 4 - Removal of Brackets on Modular Units
Horizontal Right Conversion of Units With Slope Coils
NOTE: Gasket kit number KFAHD0101SLP is required for
horizontal slope coil conversion to maintain low air leak/low sweat
performance.
1. Remove blower and coil access panel and fitting panel. (See
Fig. 50
2. Remove coil mounting screw securing coil assembly to
right side casing flange.
3. Remove coil assembly.
4. Lay fan coil unit on its right side and reinstall coil assembly
with condensate pan down. (See Fig. 5.)
5. Attach coil to casing flange using coil mounting screw pre-
viously removed.
6. Make sure the pan cap in the fitting door is properly seated
on the fitting door to retain the low air leak rating of the
unit.
7. Add gaskets from kit KFAHD per kit instructions.
8. Align holes with tubing connections and condensate pan
connections, and reinstall access panels and fitting panel.
Make sure liquid and suction tube grommets are in place to prevent
air leaks and cabinet sweating. Install after brazing.
HORIZON1AL RIGHT
A00071
Fig. 6 - Conversion for Horizontal Right Applications Using
A-Coil
2. Remove metal clip securing fitting panel to condensate pan.
Remove fitting panel.
3. Remove 2 snap-in clips securing A-coil in unit.
4. Slide coil and pan assembly out of unit.
5. Remove horizontal drain pan support bracket from coil sup-
port rail on left side of unit and reinstall on coil support rail
on right side of unit. (See Fig. 7.)
DRAINPAN
SUPPORT BRACKET
A07571
Fig. 7 - Drain Pan Support Bracket
6. Convert air-seal assembly for horizontal right.
a. Remove air-seal assembly from coil by removing 4
screws. (See Fig. 6.)
b. Remove air splitter (B) from coil seal assembly by re-
moving 3 screws. (See Fig. 3-factory shipped inset.)
c.Removefilterplate(A)andinstallairsplitter(B)in
placeoffilterplate.
d.Installfilterplate(A)asshowninhorizontalrightap-
plication.
e.Removecondensatetroughs(C)andinstallonopposite
tubesheets.
f.Installhoseontoplasticspout.
7.Installhorizontalpanonrightsideofcoilassembly.
8.Slidecoilassemblyintocasing.Besurecoilbracketoneach
cornerofverticalpanengagescoilsupportrails.
9.Reinstall2snap-inclipstocorrectlypositionandsecure
coilassemblyinunit.Besureclipwithlargeoffsetsisused
onrightsideofunittosecurehorizontalpan.
10.Removetwoovalfittingcapsfromtheleftsideofthecoil
doorandfittingpanel.
11.Removeinsulationknockoutsonrightsideofcoilaccess
panel.
12.Remove2ovalcoilaccesspanelplugsandreinstallinto
holesonleftsideofcoilaccesspanelandfittingpanel.
13.Installcondensatepanfittingcaps(fromitem10)inthe
rightsideofthecoildoormakingsurethatthecapsnaps
andseatscleanlyonthebacksideofthecoildoor.Make
surenoinsulationinterfereswithseatingofthecap.
14.Reinstallaccessfittingpanels,aligningholeswithtubing
connectionsandcondensatepanconnections.Besuretore-
installmetalclipbetweenfittingpanelandverticalcondens-
atepan.
Makesureliquidandsuctiontubegrommetsareinplacetoprevent
airleaksandcabinetsweating.
D.ManufacturedandMobileHomeHousingApplications
1.Fancoilunitmustbesecuredtothestructureusingfield-
suppliedhardware.
2.Allowaminimumof24-in(610ram)clearancefromaccess
panels.
3.Recommendedmethodofsecuringfortypicalapplications:
a.Iffancoilisawayfromwall,attachpipestraptotopof
fancoilusingno.10self-tappingscrews.Anglestrap
downandawayfrombackoffancoil,removeallslack,
andfastentowallstudofstructureusing5/16-in.lag
screws.Typicalbothsidesoffancoil.
4" (102mm) MAX
SECURE FAN COILTO STRUCTURE
UNIT AWAY FROM WALL
PIPE STRAP
(TYPICAL BOTH SIDES)
OR
UNIT AGAINST WALL
.125" (3ram)
MOUNTING BRACKET
(TYPICAL BOTH SIDES)
DOWN FLOW
BASE KIT (KFACB)
_. SECURE UNITTO FLOOR
ANGLE BRACKET OR PIPE STRAP
4" (102ram) MAX
Fig. 8 - A-Coil
A07567
b. If fan coil is against wall, secure fan coil to wall stud
using 1/8-in (3 ram) thick right-angle brackets. Attach
brackets to fan coil using no. 10 self-tapping screws
and to wall stud using 5/16-in. lag screws. (See Fig. 8.)
Step 3 -- Air Ducts
Connect supply-air duct over the outside of 3/4-in (19 ram)
flanges provided on supply-air opening. Secure duct to flange,
using proper fasteners for type of duct used, and seal duct-to-unit
joint. If return-air flanges are required, install factory-authorized
accessory kit.
Use flexible connectors between ductwork and unit to prevent
transnfission of vibration. When electric heater is installed, use
heat-resistant material for flexible connector between ductwork
and unit at discharge connection. Ductwork passing through
unconditioned space must be insulated and covered with vapor
barrier.
Units equipped with 20-30kW electric heaters require a 1-in (25
ram) clearance to combustible materials for the first 36-in (914
ram) of supply duct.
Ductwork Acoustical Treatment
Metal duct systems that do not have a 90 ° elbow and 10-fl (3m) of
main duct to first branch takeoff may require internal acoustical
insulation lining. As an alternative, fibrous ductwork may be used
if constructed and installed in accordance with the latest edition of
SMACNA construction standard on fibrous glass ducts. Both
acoustical lining and fibrous ductwork shall comply with National
Fire Protection Association as tested by UL Standard 181 for Class
1 air ducts.
Step 4 -- Electrical Connections
FY5B units from the factory utilize a printed-circuit board (PCB)
which has a low voltage circuit protective fuse (5 amp), fan motor
speed tap selection terminal (SPT), and time delay relay (TDR)
jumper. To disable the TDR feature, sever the jumper wire JW1.
(See Fig. 9.)
FB4C units from the factory protect the low voltage circuit with a 3
amp automotive type fuse inline on the wire harness and Does Not
contain a circuit board. Motor speeds and time delay function are
built into the motor (see section E for clarification).
When a factory-approved accessory control package has been
installed, check all factory wiring per unit wiring diagram and
inspect factory wiring connections to be sure none were loosened
in transit or installation. If a different control package is required,
see unit rating plate.
o8 (D<
R2 <ZEZ>
C3
R6
R!1 _{_
Rlo<ZZZ_ -- c O
R9_ C
f
R7 C _
a
C6
F1
@{) }
LF:f40061
A03010
Fig. 9 - ]Tan Coil Printed Circuit Board for ]TY5B Model
PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in product or
property damage.
If a disconnect switch is to be mounted on unit, select a
location where drill or fastener will not contact electrical or
refrigerant components.
Before proceeding with electrical connections, make certain that
supply voltage, frequency, phase, and ampacity are as specified on
the unit rating plate. See unit wiring label for proper field high-
and low-voltage wiring. Make all electrical connections in
accordance with the NEC and any local codes or ordinances that
may apply. Use copper wire only.
The unit must have a separate branch electric circuit with a
field-supplied disconnect switch located within sight from, and
readily accessible from, the unit.
On units with a factory-installed disconnect with pull-out
removed, service and maintenance can be safely performed on only
the load side of the control package.
ELECTRICALSHOCK HAZARD
Failure to follow this warning could result in personal iniury or
death.
Field wires on the line side of the disconnect found in the fan coil
unit remain live, even when the pull-out is removed. Service and
maintenance to inconfing wiring cannot be performed until the
main disconnect switch (remote to the unit) is turned off.
A. Line Voltage Connections
If unit will contain accessory electric heater, remove and discard
power plug from fan coil and connect male plug from heater to
female plug from unit wiring harness. (See Electric Heater
Installation Instructions.)
For units without electric heater:
1. Connect 208/230v power leads from field disconnect to yel-
low and black stripped leads.
2. Connect ground wire to unit ground lug.
NOTE: Units installed without electric heat should have a
field-supplied sheet metal block-off plate covering the heater
opening. This will reduce air leakage and formation of exterior
condensation.
B. 24-v Control System
Connection To Unit
Wire low voltage in accordance with wiring label on the blower.
(See Fig. 10 through 15.) Use no. 18 AWG color-coded, insulated
(35°C nfininmm) wire to make the low-voltage connections
between the thermostat, the unit, and the outdoor equipment. If the
thermostat is located more than 100-ft (30 m) from the unit (as
measured along the low-voltage wire), use no. 16 AWG
color-coded, insulated (35 °C nfininmm) wire. All wiring nmst be
NEC Class 1 and must be separated from inconfing power leads.
THERMOSTAT
[]
FAN COIL
(CONTROL}
RED R
_G
W2
W3
L_o E
A_R COND.
Fig. 10 - Wiring Layout Air Conditioning []nit
(Cooling Only)
TH ERMOSTAT
E]-
[Eb
FAN COIL
(CONTROL)
R
G
W2
W3
E
C
AIR COND.
Fig. 11 - Wiring Layout Air Conditioning []nit
(Cooling and 1-Stage Heat)
FAN COIL
THERMOSTAT (CONTROL)
EP
[]
[]
Eb m
-_Y G
W3
h / wo __
HEAT PUMP
(CONTROL)
R
C2x_ c
w2
o
y
Fig. 12 - Wiring Layout Heat Pump []nit
(Cooling and 2-Stage Heat with
No Outdoor Thermostat)
A94058
A94059
A94060
THERMOSTAT
[27b
[]
FANCOIL
(CONTROL)
HEAT PUMP
(CONTROL)
R
G
c
W2
E
W3 S
C
R
C
W2
o
Y
Fig. 13 - Wiring Layout Heat Pump Unit
(Cooling and 2-Stage Heat with
1 Outdoor Thermostat)
FAN COIL
(CONTROL)
R
G
_ BR_ C
_ WH] W2 _
BLU
w3
v!o
ODT
ODT
THERMOSTAT HEAT PUMP
(CONTROL)
R
C
W2
O
Y
A94061
EMERGENCY HEAT RELAY
A94062
Fig. 14 - Wiring Layout Heat Pump Unit (Cooling and
2-Stage Heat with 2 Outdoor Thermostats)
[]
[]
[]
[]
THERMOSTAT FAN COIL
(CONTROL)
HEAT PUMP
(CONTROL)
R
C
,[ w2
O
v
A0a088
Fig. 15 - Wiring Layout Heat Pump Unit
(Cooling and 2-Stage Heat for Manufactured Housing)
Refer to outdoor unit wiring instructions for any additional wiring
procedure recommendations.
Transformer Information
Transformer is factory-wired for 230v operation. For 208v
applications, disconnect the black wire from the 230v terminal on
transformer and connect it to the 208v terminal. (See Fig. 16.)
RED
YEL
Fig. 16 - Transformer Connections
Heater Staging
A05182
PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in product or
property damage.
If W2, W3, and E on any 3 stage heater (18, 20, 24, or
30kW) are individually connected as with outdoor
thermostats or any other situation, emergency heat relay must
be used. This relay is in kit Part No. KHOT0201SEC and is
normally used with kit Part No. KHAOT0301FST for 2
outdoor thermostat systems.
The controls are factory circuited for single-stage operation. For
2-stage operation, use outdoor thermostat kit Part No.
KHAOT0301FST, and for 3-stage use both kits Part No.
KHAOT0201SEC and KHAOT0301FST.
When 2 stages are desired, cut W3 at the W2 wire nut, strip and
reconnect per the thermostat kit instruction. (See Fig. 14.) When 3
stages are desired, cut the W2 wire nut off and discard. Strip W2,
W3, and E and reconnect per thermostat kit instructions. (See Fig.
14.)
NOTE: When 3 stages are used or anytime the E terminal is not
tied to W2, the emergency heat relay, part of outdoor kit Part No.
KHAOT0201SEC nmst be used.
C. Manufactured Housing
In manufactured housing applications, the ('ode of Federal
Regulations, Title 24, Chapter XX, Part 3280.714 requires that
supplemental electric heat be locked out at outdoor temperatures
above 40°F (4°C), except for a heat pump defrost cycle. Refer to
Fig. 15 for typical low voltage wiring with outdoor thermostat.
D.GroundConnections
ELECTRICALSHOCKHAZARD
Failureto follow this warning could result in personal iniury
or death.
According to NEC, ANSI/NFPA 70, and local codes, the
cabinet must have an uninterrupted or unbroken ground to
minimize personal iniury if an electrical fault should occur.
The ground may consist of electrical wire or metal conduit
when installed in accordance with existing electrical codes. If
conduit connection uses reducing washers, a separate ground
wire must be used.
NOTE: Use UL-listed conduit and conduit connector for
connecting supply wire(s) to unit to obtain proper grounding.
Grounding may also be accomplished by using grounding lugs
provided in control box.
E. Minimum CFM and Motor Speed Selection
Units with or without electric heaters require a minimum CFM.
Refer to the unit wiring label to ensure that the fan speed selected is
not lower than the minimum fan speed indicated.
FY5B fan speed selection is done at the fan relay printed-circuit
board. To change motor speeds, disconnect fan lead used on relay
terminal (SPT) and replace with motor speed tap desired. (See Fig.
17.) Save insulating cap and place on motor lead removed from
relay.
NOTE: In low static applications, lower motor speed tap should
be used to reduce possibility of water being blown off coil.
FY5B have 2 motor speed taps. Low speed (red) and high speed
(black). The 060 size only will have a Medium speed (blue).
See Table 2 - FY5B Airflow Performance (CFM), for each setting.
INSULATING CAP (2)
MOTOR 8
A97529
Fig. 17 - Fan Coil Relay and Speed Tap Terminal
for FY5B Models
The fan speed selection on the FB4C models is done at the motor.
Units with or without electric heaters require a minimum CFM.
Refer to the unit wiring label to ensure that the fan speed selected is
not lower than the minimum fan speed indicated. To change motor
speeds disconnect the BLUE fan lead from terminal #2 (factory
default position) and move to desired speed-tap; 1, 2, 3, or 5.
Speed-taps 1, 2, and 3 have a 90 second blower time delay
pre-programmed into the motor. Speed tap 4 is used for electric
heat only (with 0 second blower time delay) and the WHITE wire
must remain on tap 4. Speed-tap 5 is used for high static
applications, but has a 0 second blower time delay
pre-programmed into the motor (see Table 1 - FB4C Airflow
Performance (CFM), for each tap setting. Also, see Fig. 18 for
motor speed selection location.
NOTE: In low static applications, lower motor speed tap should
be used to reduce possibility of water being blown off coil.
F
Fig. 18 - Motor Speed Selection
A09390
Step 5 -- Refrigerant Tubing Connection and
Evacuation
Use accessory tubing package or field-supplied tubing of
refrigerant grade. Suction tube must be insulated. Do not use
damaged, dirty, or contaminated tubing because it may plug
refrigerant flow-control device. ALWAYS evacuate the coil and
field-supplied tubing to 500 microns before opening outdoor unit
service valves.
PRODUCT DAMAGE HAZARD
Failure to follow this caution may result in product or
property damage.
A brazing shield MUST be used when tubing sets are being
brazed to the unit connections to prevent damage to the unit
surface and condensate pan fitting caps.
Units have sweat suction and liquid tube connections. Make
suction tube connection first.
1. Cut tubing to correct length.
2. Insert tube into sweat connection on unit until it bottoms.
3. Braze connection using silver bearing or non-silver bearing
brazing materials. Do not use solder (materials which melt
below 800°F / 427°C). Consult local code requirements.
4. Evacuate coil and tubing system to 500 microns using deep
vacuum method.
PRODUCT DAMAGE HAZARD
Failure to follow this caution may result in product or
property damage.
Wrap a wet cloth around rear of fitting to prevent damage to
piston assembly or TXV and factory-made joints.
Step 6 -- Refrigerant Flow-Control Device
FB4C units come equipped with a factory installed Piston with
Teflon ring metering device (sizes 018 thru 060). If a piston
replacement if required, check piston size shown on indoor unit
ratingplateto see if it matches required piston shown on outdoor
unit rating plate. If it does not match, replace indoor piston with
piston shipped with outdoor unit. The piston shipped with outdoor
unit is correct for any approved indoor coil combination (See Fig.
19). When changing piston, use a back-up wrench. Hand tighten
hex nut, then tighten with wrench 1/2 turn. Do not exceed 30
ft-lbs.
NOTE: The indoor piston contains a Teflon ring (or seal) which is
used to seat against the inside of distributor body, and must be
installed properly to ensure proper seating in the direction for
cooling operation.
FY5B units also contain a factory installed Piston with Teflon ring
for sizes 018 thru 048 only. The FY5B-060 size units come
equipped with a Puron refrigerant TXV.
Always use outdoor units designed to match indoor fan coil
applications.
BRASS_
HEX NUT\ TEFLON SEAL
\
)_, TEFLON RiNG
PISTON
l
1
1
FLOW iN
COOLING
PISTON
RETAINER
BRASS
HEX BODY
STRAINER
[]NIT OR PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in product or
property damage.
The conversion of the fan coil to downflow requires special
procedures for the condensate drains on both A-coil and
slope units. The vertical drains have an overflow hole
between the primary and secondary drain holes. This hole is
plugged for all applications except downflow, but must be
used for downflow. During the conversion process, remove
the plastic cap covering the vertical drains only and discard.
Remove the plug from the overflow hole and discard. At
completion of the downflow installation, caulk around the
vertical pan fitting to door joint to retain the low air leak
performance of the unit.
Units are equipped with primary and secondary 3/4-in. FPT drain
connections. For proper condensate line installations see Fig. 1, 2,
3, 5 and 6. To prevent property damage and achieve optimum
drainage performance, BOTH primary and secondary drain lines
should be installed and include properly-sized condensate traps.
(See Fig. 20 and 21.) Factory-approved condensate traps are
available. It is recommended that PVC fittings be used on the
plastic condensate pan. Finger-tighten plus 1-1/2 turns. Do not
over-tighten. Use pipe dope.
PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in product or
property damage.
Shallow running traps are inadequate and DO NOT allow
proper condensate drainage. (See Fig. 22.)
A09677
Fig. 19 - Refrigerant Flow - Control Device
PRODUCT OPERATION HAZARD
Failure to follow this caution may result in improper product
operation.
If using a TXV in conjunction with a single-phase
reciprocating compressor, a compressor start capacitor and
relay are required. Consult outdoor unit pre-sale literature for
start assist kit part number.
Step 7 -- Condensate Drains
To connect drains, the cap openings must be removed. Use a knife
to start the opening near the tab and using pliers, pull the tab to
remove the disk. Clean the edge of the opening if necessary and
install the condensate line. Finally caulk around the lines where
they exit the fitting to retain the low leak rating of the unit.
UNiT
f
2" M[N
(51 ram)
Fig. 20 - Recommended Condensate Trap
A03002
PRIMARY TRAP R EQU]RF_NXD_
(USE FACTORY KIT OR
FIELD SUPPUEDTRAP OF
SUFHCIENT DEPTH
S1ANDARD P TRAPS ARE
NOT SUFFICIENT SEE
RGURE OF REODMMENDED
CONDENSATE TRAP)
- s
- SECONDARY DRAIN WITH
APPROPRIATE TRAP REQUIRED
(USE FACTORY KIT OR
FIELD SUPPUED TRAP)
Fig. 21 - Condensate Trap and Unit
A03003
DO NOT USE SHALLOW RUNNING TRAPS!
A03013
Fig. 22 - Insufficient Condensate Trap
NOTE: When connecting condensate drain lines, avoid blocking
filter access panel, thus preventing filter removal. After connection,
prime both primary and secondary condensate traps.
NOTE: If unit is located in or above a living space where damage
may result from condensate overflow, a field-supplied, external
condensate pan should be installed underneath the entire unit, and a
secondary condensate line (with appropriate trap) should be run
from the unit into the pan. Any condensate in this external
condensate pan should be drained to a noticeable place. As an
alternative to using an external condensate pan, some localities
may allow the use of a separate 3/4-in (19 ram) condensate line
(with appropriate trap) to a place where the condensate will be
noticeable. The owner of the structure must be informed that when
condensate flows from the secondary drain or external condensate
pan, the unit requires servicing or water damage will occur.
Install traps in the condensate lines as close to the coil as possible.
(See Fig. 21.) Make sure that the outlet of each trap is below its
connection to the condensate pan to prevent condensate from
overflowing the drain pan. Prime all traps, test for leaks, and
insulate traps if located above a living area. Condensate drain lines
should be pitched downward at a minimum slope of l-in (25 ram)
for every 10-fl (3 m) of length. Consult local codes for additional
restrictions or precautions.
Step 8 -- Accessories
A. Electronic Air Cleaner
The Electronic Air ('leaner may be connected to fan coil as shown
in Fig. 23. This method requires a field supplied transformer. See
Electronic Air Cleaner literature for kit requirements.
B. Humidifier
Connect humidifier and humidistat to fan coil unit as shown in Fig.
24 and Fig. 25. The cooling lockout relay is optional.
CONTROL BOARD
R G T C C C
II
COM
TO EAC
208/
23O
FROM MOLEX
PLUG AND
TRANSFORMER
(IN UNIT)
A03011
Fig. 23 - Wiring Layout of Electronic Air Cleaner to Fan Coil
for FY5B Models Only
THERMOSTAT HEAT PUMP
(CONTROL)
[]
[]
i
I.......
i
J
RELAY
i
i
i
[ HUMIDISTAT
R
C
W2
0
Y
A95294
Fig. 24 - Wiring Layout of Humidifier to Heat Pump
THERMOSTAT
[2b
FANCOIL
(CONTROL)
R
G
W2
W3
E
Z_ BBRNRN AIR COND.c
__ i [ HUMID!STAT
A95295
Fig. 25 - Wiring Layout of Humidifier to Fan (:oil
With Electric Heat
Step 9 -- Sequence of Operation
A. Continuous Fan
Thermostat closes R to G. G energizes fan relay on PCB which
completes circuit to indoor blower motor. When G is de-energized,
there is a 90-sec delay before relay opens.
B. Cooling Mode
Thermostat energizes R to G, R to Y, and R to O (heat pump only).
G energizes fan relay on PCB which completes circuit to indoor
blower motor. When G is de-energized, there is a 90-sec delay
before fan relay opens.
C. Heat Pump Heating with Auxiliary Electric Heat
Thermostat energizes R to G, R to Y, and R to W. G energizes fan
relay on PCB which completes circuit to indoor blower motor. W
energizes electric heat relay(s) which completes circuit to heater
element(s). When W is de-energized, electric heat relay(s) open,
turning off heater elements. When G is de-energized there is a
90-sec delay before fan relay opens.
D. Electric Heat or Emergency Heat Mode
Thermostat closes R to W. W energizes electric heat relay(s) which
completes circuit to heater element(s). Blower motor is energized
through normally closed contacts on fan relay. When W is
de-energized, electric heat relay(s) opens.
START-UP PROCEDURES
Refer to outdoor unit Installation Instructions for system start-up
instructions and refrigerant charging method details.
[]NIT COMPONENT HAZARD
Failure to follow this caution may result in product damage.
Never operate unit without a filter. Damage to blower motor
or coil may result. Factory authorized filter kits nmst be used
when locating the filter inside the unit. For those applications
where access to an internal filter is impractical, a
field-supplied filter must be installed in the return duct
system.
CARE AND MAINTENANCE
To continue high performance and minimize possible equipment
failure, it is essential that periodic maintenance be performed on
this equipment. Consult your local dealer as to the proper
frequency of maintenance contract.
The ability to properly perform maintenance on this equipment
requires certain mechanical skills and tools. If you do not possess
these, contact your dealer for maintenance. The only consumer
service recommended or required is filter replacement or cleaning
on a monthly basis.
10
AIRFLOW PERFORMANCE TABLES
Table 1 - FB4C Airflow Performance (CFM)
MODEL & SIZE BLOWER SPEED 0.10 0.20 0.30 0.40 0.50 0.60
Tap 5 669 620 565
Tap 4 614 569 534 486 436 398
FB4C 018 Tap 3 660 616 581 537 499
Tap 2 614 569 534 486 436 398
Tap 1 614 569 534 486 436 398
Tap 5 892 835 763 676
Tap 4 826 795 766 743 706 660
FB4C 024 Tap 3 826 795 766 743 706 660
Tap 2 701 660 616 581 537 499
Tap 1 617 592 552 507 472 420
Tap 5 1108 1090 1065 1034 1009 974
Tap 4 1026 1000 969 938 899 865
FB4C 030 Tap 3 1026 1000 969 938 899 865
Tap 2 909 873 842 799 762 724
Tap 1 825 795 757 722 674 634
Tap 5 1301 1276 1245 1218 1176 1121
Tap 4 1227 1191 1169 1143 1105 1074
FB4C 036 Tap 3 1227 1191 1169 1143 1105 1074
Tap 2 1087 1062 1030 1001 966 930
Tap 1 1026 1000 969 938 899 865
Tap 5 1560 1544 1507 1464 1424 1358
Tap 4 1419 1397 1358 1320 1279 1239
FB4C 042 Tap 3 1419 1397 1358 1320 1279 1239
Tap 2 1249 1220 1184 1142 1093 1052
Tap 1 1242 1205 1158 1110 1069 1026
Tap 5 1743 1712 1679 1642 1610 1574
Tap 4 1669 1634 1599 1564 1531 1499
FB4C 048 Tap 3 1669 1634 1599 1564 1531 1499
Tap 2 1452 1413 1377 1339 1308 1271
Tap 1 1300 1256 1221 1182 1142 1101
Tap 5 1897 1867 1836 1808 1774 1736
Tap 4 1817 1785 1757 1724 1693 1655
FB4C 060 Tap 3 1817 1785 1757 1724 1693 1655
Tap 2 1657 1621 1589 1557 1518 1474
Tap 1 1443 1412 1377 1332 1286 1243
Table 2 - FY5B Airflow Performance (CFM)
0.10 0.20 0.30 0.40
208V 230V 208V 230V
541 608 480 564
041 :_1_:30
MODEL &
SIZE
FY5B 018
FY5B 024
FY5B 030
FY5B 036
FY5B 042
FY5B 048
FY5B 060
BLOWER
SPEED
High
Low
High
Low
High
Low
High
Low
High
Low
High
Low
High
Medium
Low
- Airflow outside 450 cfm/ton
NOTES:
965 1117 949 1074
1306 1264
1164 1335 1144 1290
1387 1543 1358 1488
1803
1671 1777 1630 1711
2064 2128 1989 2050
1812 1959 1756 1898
1556 1748 1521 1709
0.50 0.60
208V 230V 208V 230V 208V 230V 208V 230V
642 568 648 466 526 403 434
417 511 357 431 299 363 304
888 774 791 573 654 341 438
781 868 684 740 506 573 341 418
1071 1132 952 1005 704 791 459 482
916 1019 805 902 575 637 396 447
1207 1338 1135 1241 1043 1127 842 937
1108 1226 1052 1148 970 1048 697 855
1544 1576 1435 1465 1309 1340 1144 1182
1311 1410 1237 1315 1137 1200 997 1047
1706 1767 1593 1648 1472 1512 1303 1371
1563 1630 1479 1528 1370 1412 1218 1266
1906 1965 1819 1875 1725 1778 1624 1674
1692 1829 1619 1750 1538 1663 1449 1566
1477 1659 1422 1598 1357 1525 1283 1442
1. Airflow based upon dry coil at 230v with factory-approved filter and electric heater (2 element heater sizes 018 through 036, 3 element
heater sizes 042 through 060). For FB4C models, airflow at 208 volts is approximately the same as 230 volts because the X13 motor is a
constant torque motor. The torque doesn't drop off at the speeds the motor operates.
2. To avoid potential for condensate blowing out of drain pan prior to making drain trap:
Return static pressure must be less than 0.40 in. wc.
Horizontal applications of 042 - 060 sizes must have supply static greater than 0.20 in. wc.
3. Airflow above 400 cfm/ton on 048-060 size could result in condensate blowing off coil or splashing out of drain pan.
11
Table3 - FB4C Air Delivery Performance Correction Component Pressure Drop (in. wc) at Indicated Airflow (Dry to Wet Coil)
CFM
UNIT SIZE
500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000
018 0.034 0.049 0.063 ..........................
024 0.064 0.049 0.066 0.076 0.089 ......................
030 ...... 0.049 0.059 0.070 0.080 ..................
066 .......... 0.070 0.080 0.090 0.099 ..............
042 .............. 0.049 0.056 0.066 0.070 ..........
048 .................. 0.066 0.070 0.076 0.086 0.090 ....
060 ...................... 0.049 0.054 0.059 0.065 0.070
Table 4 - FYSB Air Delivery Performance Correction Component Pressure Drop (in. wc) at Indicated Airflow (Dry to Wet Coil)
CFM
UNIT SIZE
500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000
018 0.016 0.027 0.068 ..........................
024 0.016 0.027 0.068 0.049 0.059 ......................
030 ...... 0.036 0.046 0.055 0.064 ..................
036 .......... 0.055 0.064 0.073 0.081 ..............
042 .............. 0.049 0.056 0.066 0.070 ..........
048 .................. 0.068 0.046 0.049 0.054 0.059 ....
060 ...................... 0.061 0.066 0.040 0.044 0.049
Table 5 - FB4C Electric Heater Static Pressure Drop (in. wc)
CFM
UNIT SIZE
400 600 800 1000 1200 1400 1600 1800 2000
018, 024 0.020 0.044 0.075 ............
060, 066 .... 0.048 0.072 O.1O0 ........
042, 048, 060 ........ 0.070 0.092 0.120 0.152 --
Table 6 - FY5B Electric Heater Static Pressure Drop (in. wc)
CFM
UNIT SIZE
400 600 800 1000 1200 1400 1600 1800 2000
018, 024 0.020 0.044 0.075 0.110 0.1 O0 ........
060, 066, 042 .... 0.048 0.072 0.100 0.160 0.120 ....
048, 060 .......... 0.092 0.120 0.152 0.187
Table 7 - Electric Heater Static Pressure Drop (in. wc)
FB4C, FY5B FB4C, FY5B
018 - 036 042 - 060
HEATER EXTERNAL STATIC HEATER EXTERNAL STATIC
kW PRESSURE kW PRESSURE
ELEMENTS CORRECTION ELEMENTS CORRECTION
0 0 + .02 0 0 + .04
1 3, 5 +.01 2 8, 10 +.02
2 8, 10 0 3 9, 15 0
3 9, 15 -.02 4 20 -.02
4 20 -.04 6 18, 24, 30 -.10
12
PURON® (R-410A) QUICK REFERENCE GUIDE
Puron refrigerant operates at 50-70 percent higher pressures than R-22. Be sure that servicing equipment and replacement
components are designed to operate with Puron refrigerant.
Puron refrigerant cylinders are rose colored.
Recovery cylinder service pressure rating must be 400 psig, DOT 4BA400 or DOT BW400.
Puron refrigerant systems should be charged with liquid refrigerant. Use a commercial type metering device in the manifold hose
when charging into suction line with compressor operating
Manifold sets should be 700 psig high side and 180 psig low side with 550 psig low-side retard.
Use hoses with 700 psig service pressure rating.
Leak detectors should be designed to detect HFC refrigerant.
Puron refrigerant, as with other HFCs, is only compatible with POE oils.
Vacuum pumps will not remove moisture from oil.
Do not use liquid-line filter driers with rated working pressures less than 600 psig.
Do not leave Puron refrigerant suction line filter driers in line longer than 72 hours.
Do not install asuction-line filter drier in liquid line.
POE oils absorb moisture rapidly. Do not expose oil to atmosphere.
POE oils may cause damage to certain plastics and roofing materials.
Wrap all filter driers and service valves with wet cloth when brazing.
A factory approved liquid-line filter drier is required on every unit.
Do NOT use an R-22 TXV.
If indoor unit is equipped with a R-22 TXV or piston metering device, it must be changed to a hard-shutoff Puron refrigerant
TXV.
Never open system to atmosphere while it is under a vacuum.
When system must be opened for service, recover refrigerant, evacuate then break vacuum with dry nitrogen and replace filter
driers. Evacuate to 500 microns prior to recharging.
Do not vent Puron refrigerant into the atmosphere.
Do not use capillary tube coils.
Observe all warnings, cautions, and bold text.
All indoor coils must be installed with a hard-shutoff Puron refrigerant TXV metering device.
13
Copyright 2007 CAC / BDP 7310 W. Morris St. Indianapolis, IN 46231 Printed in U,S,A, Edition Date: 12/09
Manufacturer reserves the right to change, at any time, specification8 and design8 without notice and without obligations,
Catalo_ No: IM-FB4CNF-01
Replaces: NEW
14
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Carrier fy5b Installation Instructions Manual

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